US9133537B2 - Superalloy component and method of improving the same - Google Patents

Superalloy component and method of improving the same Download PDF

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Publication number
US9133537B2
US9133537B2 US13/263,011 US201013263011A US9133537B2 US 9133537 B2 US9133537 B2 US 9133537B2 US 201013263011 A US201013263011 A US 201013263011A US 9133537 B2 US9133537 B2 US 9133537B2
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surface layer
slurry
component
additive
superalloy
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US20120085468A1 (en
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Paul Mathew Walker
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Siemens AG
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Siemens AG
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/007—Alloys based on nickel or cobalt with a light metal (alkali metal Li, Na, K, Rb, Cs; earth alkali metal Be, Mg, Ca, Sr, Ba, Al Ga, Ge, Ti) or B, Si, Zr, Hf, Sc, Y, lanthanides, actinides, as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/07—Alloys based on nickel or cobalt based on cobalt
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/18—Solid state diffusion of only metal elements or silicon into metallic material surfaces using liquids, e.g. salt baths, liquid suspensions
    • C23C10/20—Solid state diffusion of only metal elements or silicon into metallic material surfaces using liquids, e.g. salt baths, liquid suspensions only one element being diffused
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/18—Solid state diffusion of only metal elements or silicon into metallic material surfaces using liquids, e.g. salt baths, liquid suspensions
    • C23C10/26—Solid state diffusion of only metal elements or silicon into metallic material surfaces using liquids, e.g. salt baths, liquid suspensions more than one element being diffused
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C10/00—Solid state diffusion of only metal elements or silicon into metallic material surfaces
    • C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
    • C23C10/30—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes using a layer of powder or paste on the surface
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • C23C24/106—Coating with metal alloys or metal elements only
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
    • C23C26/02—Coating not provided for in groups C23C2/00 - C23C24/00 applying molten material to the substrate

Definitions

  • the present invention relates to a superalloy component and to a method of improving a superalloy component.
  • Components that are exposed to hot corrosive gases like for example gas turbine components which are exposed to the hot and corrosive combustion gas, are typically made of superalloys which offer a high strength at elevated temperatures.
  • Such superalloys are usually based on nickel (Ni), cobalt (Co) or iron (Fe). Although superalloys show high strength at temperatures up to 1200° C. and more they need to be protected from oxidation and/or corrosion.
  • This protection is typically provided by an alumina scale which is either formed in the surface of the superalloy component or by so called MCrAlY-overlay coatings, in which M stands for nickel, cobalt or iron and Y represents yttrium (Y), hafnium (Hf), or a rare earth element.
  • M stands for nickel, cobalt or iron
  • Y represents yttrium (Y), hafnium (Hf), or a rare earth element.
  • Y yttrium
  • Hf hafnium
  • a rare earth element a rare earth element.
  • Such coatings are, for example, known from EP 0 486 489 B1, EP 0 786 017 B1, or EP 1 306 456 A1. From U.S. Pat. No. 4,615,864 it is known that addition of hafnium, yttrium or lanthanum (La) to the MCrAlY composition is beneficial because the oxides of these materials assist in pinning the alumina
  • a coating may also be called Thermal Barrier Coating (TBC) if it is intended to provide thermal insulation, e.g. of turbine aerofoils of gas turbines.
  • TBC Thermal Barrier Coating
  • a superalloy component in particular a nickel based superalloy component, a cobalt based superalloy component or an iron based superalloy component is improved by at least one additive chosen from the group of Hf, La, and Y.
  • the at least one additive is introduced into a surface layer of the component.
  • the surface layer may have a depth of 0.5 mm or less, preferably 0.25 mm or less.
  • Introducing at least one additive chosen from the group of hafnium, lanthanum and yttrium into the surface layer of a superalloy component improves the component in that a later applied thermal barrier coating (TBC) including a MCrAlY-coating shows an improved oxidation resistance due to the additives.
  • TBC thermal barrier coating
  • the improved oxidation resistance increases lifetime of the coating.
  • pinning of the protective oxide scale in the MCrAlY-coating is improved, too, which also improves lifetime of the coating.
  • the scope of the invention also includes the presence of at least two additives chosen from the group of hafnium, lanthanum and yttrium, or the case where all three elements are present. If at least two additives chosen from the mentioned group are present the additives can be introduced after each other into a surface layer of the component, or they can be introduced simultaneously. In case all three elements are present as additives either all three can be introduced after one another or simultaneously. A further alternative is to introduce the additives with two of the elements introduced simultaneously while the third one is introduced before or after the other two.
  • hafnium is used as additive it is introduced into the surface layer up to an amount of 5%, preferably up to an amount of 1% by weight of the material composition of the surface layer. If yttrium is used as additive it is introduced into the surface layer up to an amount of 0.2%, preferably up to an amount of 0.05% by weight of the material composition of the surface layer. If lanthanum is used as additive it is introduced into the surface layer up to an amount of 0.2%, preferably up to an amount of 0.05% by weight of the material composition of the surface layer.
  • the at least one additive may be introduced into the surface layer by melting it into the surface.
  • the at least one additive may be introduced into the surface layer by diffusing it into the surface layer.
  • Melting the additive into the surface layer may be accomplished by heating the surface, in particular by locally heating surface, e.g., by means of laser. Locally heating the surface allows for locally melting the surface and for letting the melted surface solidify in a directionally oriented manner so that this method of introducing the additive is useful if the inventive method is to be applied to a single crystal or directionally solidified superalloy component. In such a local heating method the surface would be scanned by the heating means, e.g. by the mentioned laser.
  • the diffusing can be accomplished by usual heat treatments as they are known by a person skilled in the art.
  • a slurry matrix containing at least one additive can be applied onto the surface.
  • the surface is then heated locally or globally with the slurry applied thereon.
  • a slurry matrix would advantageously comprise the base material of the superalloy, i.e. nickel in case of a nickel based superalloy, cobalt in case of a cobalt based superalloy and iron in case of an iron based superalloy, and an organic binder.
  • Organic binders can, in particular be chromate and phosphate organic binders.
  • an oxidation and/or corrosion resistant coating e.g. in form of a thermal barrier coating, is applied onto the surface of the superalloy component after the additive has been introduced into the surface layer of the component.
  • a thermal barrier coating would advantageously comprise a MCrAlY-coating to achieve the benefit of the mentioned assist in pinning the alumina scale by the additive introduced into the superalloy component surface layer.
  • An inventive supperalloy component has a surface layer comprising an additive chosen from the group of hafnium, lanthanum and yttrium. This surface layer may have a depth of 0.5 mm or less, preferably 0.25 mm or less.
  • the superalloy component can comprise an oxidation and/or corrosion resistant coating on the surface layer.
  • This coating may, in particular, be a thermal barrier coating comprising a MCrAlY-coating.
  • inventive superalloy component may, in particular, be made of superalloy material which is a single crystal material or a directionally solidified material.
  • FIG. 1 schematically shows an embodiment of the inventive method of improving a superalloy component.
  • FIG. 2 shows an embodiment of the inventive superalloy component.
  • the at least one additive is introduced into a surface layer of the component 1 , which may be a gas turbine component such as, for example, a turbine vane or blade or a liner element of a hot gas path in the gas turbine.
  • the additive is introduced into a surface layer 7 of the superalloy component 1 by means of a slurry 3 containing the additive.
  • the slurry is applied onto the surface of the component l and then the slurry 3 is heated in order to melt the additives into the surface layer 7 of the component.
  • the heating is implemented by a local heating process in which the location of the local heating is moved over the surface.
  • the slurry is formed comprising a solid content and an organic binder.
  • the solid content includes, for example in form of a powder, in form of flakes, et cetera, the base material of the superalloy component and a certain amount of hafnium and/or lanthanum and/or yttrium. If, for example the superalloy component is made of a nickel based superalloy the solid content would contain nickel which would be the major part of the solid content.
  • the organic binder can, for example, be an organic binder comprising chromate and phosphate. The organic binder could be present in an amount between 40% and 70% by weight of the slurry.
  • the amount of hafnium can be between 0 and 2,5% by weight of the slurry, preferably between 0 and 1% by weight of the slurry.
  • the amount of yttrium can be between 0 and 0.1% by weight of the slurry, preferably between 0 and 0.05% by weight of the slurry.
  • the amount of lanthanum can be between 0 and 0.1% by weight of the slurry, preferably between 0 and 0.05% by weight of the slurry.
  • the balance of the slurry would substantially be the base material of the superalloy. Producing the slurry would be done by giving the solid content into the organic binder followed by a thorough mixing to form a homogenous slurry.
  • the slurry is applied onto the surface of the superalloy component 1 to form a slurry layer 3 , as it is shown in FIG. 1 .
  • Applying the slurry onto the surface of the superalloy component 1 can be done by any suitable method, for example by spraying the slurry onto the surface of the component 1 and subjecting the component with the slurry applied thereon to a heat treatment with a temperature between 300° C. and 400° C., for example approximately 350° C. to cure the slurry.
  • the surface is scanned by a laser beam 5 to locally melt the solid content of the slurry and a surface layer 7 of the superalloy component 1 .
  • the superalloy component 1 is a directionally solidified component in which crystallographic grains are elongated along a common preferred direction. It could be however, as well be a single crystal component or a component without any preferred crystal direction.
  • the laser beam 5 is moved over the surface of the superalloy component 1 along a direction which is determined by the preferred direction of extension of the grains in the superalloy material.
  • the movement is schematically indicated by an arrow in FIG. 1 .
  • the superalloy component 1 of the present embodiment is a directionally solidified component it could as well be a single crystal component since locally heating the surface of the single crystal superalloy component could be used in the same manner as described above for letting the melt solidify with continuing the crystal structure of the bulk material of the superalloy component 1 so that after solidification the surface layer 7 forms a single crystal with the bulk of the component 1 .
  • the described procedure can, in principle, also be used with a superalloy component not having a directionally solidified or a single crystal structure.
  • the hafnium and/or the lanthanum and/or yttrium is introduced into the surface layer 7 .
  • the organic components of the slurry volatize or, if they do not volatize, become brittle so that they can easily be removed from the surface, for example by slightly blasting the surface.
  • the additive i.e. the hafnium and/or lanthanum and/or yttrium
  • the additive has been melted into the surface layer 7 of the superalloy component.
  • the superalloy component 1 with the cured slurry layer 3 on the surface would be subjected to heat treatment the temperatures of which would be chosen such as to cause diffusion of the additive into the surface layer 7 of the superalloy component 1 .
  • This method of introducing the additive into the surface layer 7 is in particularly useful if there is no need for a surface layer 7 having a directionally solidified or single crystal structure.
  • thermal barrier coating 9 comprising a ceramic coating 11 is applied onto the component surface.
  • the thermal barrier coating can, for example, be a zirconia layer 11 the crystal structure of which is at least partially stabilized by yttrium, and a MCrAlY-layer 13 located between a zirconia layer 11 and the surface layer 7 of the superalloy component 1 .
  • MCrAlY-coatings and yttrium stabilized zirconia coatings as well as the methods of applying such coatings are known from the state of the art and will, therefore, not be explained here.
  • a protective alumina scale forms which is pinned to the surface of the superalloy component 1 .
  • Hafnium and/or yttrium and/or lanthanum assists in pinning the protective scale.
  • the result of the inventive method according to the described embodiment is an embodiment of an inventive superalloy component 1 , as it is shown in FIG. 2 .
  • the superalloy component 1 with the surface layer 7 containing hafnium and/or yttrium and/or lanthanum and the thermal barrier coating 9 applied thereon.
  • the superalloy component according to the invention does not need to have the described thermal barrier coating or it could have a different kind of oxidation and/or corrosion resistant coating system forming an alumina sale.
  • a superalloy component is improved by introducing hafnium and /or hafnium and/or yttrium and/or lanthanum into a surface layer of the component.
  • this allows for improving the properties of an oxidation and/or corrosion resistant coating applied on such an improved superalloy component.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
US13/263,011 2009-04-09 2010-02-18 Superalloy component and method of improving the same Expired - Fee Related US9133537B2 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP20090005237 EP2239351B1 (de) 2009-04-09 2009-04-09 Einführung von zumindest einem der Elemente von Hafnium, Lanthan und Yttrium in eine Superlegierungskomponente
EP09005237.4 2009-04-09
EP09005237 2009-04-09
PCT/EP2010/052016 WO2010115653A2 (en) 2009-04-09 2010-02-18 Superalloy component and method of improving the same

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Publication Number Publication Date
US20120085468A1 US20120085468A1 (en) 2012-04-12
US9133537B2 true US9133537B2 (en) 2015-09-15

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US (1) US9133537B2 (de)
EP (2) EP2239351B1 (de)
JP (1) JP2012523495A (de)
CN (1) CN102482757A (de)
ES (1) ES2403111T3 (de)
RU (1) RU2011145280A (de)
WO (1) WO2010115653A2 (de)

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FR3052464B1 (fr) * 2016-06-10 2018-05-18 Safran Procede de protection contre la corrosion et l'oxydation d'une piece en superalliage monocristallin a base de nickel exempt d'hafnium
FR3052463B1 (fr) * 2016-06-10 2020-05-08 Safran Procede de fabrication d'une piece en superalliage a base de nickel contenant de l'hafnium
US11692488B2 (en) 2020-11-04 2023-07-04 Delavan Inc. Torch igniter cooling system
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US11473505B2 (en) 2020-11-04 2022-10-18 Delavan Inc. Torch igniter cooling system
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US11486309B2 (en) 2020-12-17 2022-11-01 Delavan Inc. Axially oriented internally mounted continuous ignition device: removable hot surface igniter
US11754289B2 (en) 2020-12-17 2023-09-12 Delavan, Inc. Axially oriented internally mounted continuous ignition device: removable nozzle
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US11680528B2 (en) 2020-12-18 2023-06-20 Delavan Inc. Internally-mounted torch igniters with removable igniter heads
US11209164B1 (en) 2020-12-18 2021-12-28 Delavan Inc. Fuel injector systems for torch igniters
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US4615864A (en) 1980-05-01 1986-10-07 Howmet Turbine Components Corporation Superalloy coating composition with oxidation and/or sulfidation resistance
EP0207874A2 (de) 1985-05-09 1987-01-07 United Technologies Corporation Schutzschichten für Superlegierungen, gut angepasst an die Substrate
EP0486489B1 (de) 1989-08-10 1994-11-02 Siemens Aktiengesellschaft Hochtemperaturfeste korrosionsschutzbeschichtung, insbesondere für gasturbinenbauteile
US5240491A (en) 1991-07-08 1993-08-31 General Electric Company Alloy powder mixture for brazing of superalloy articles
US5622638A (en) 1994-08-15 1997-04-22 General Electric Company Method for forming an environmentally resistant blade tip
EP0786017B1 (de) 1994-10-14 1999-03-24 Siemens Aktiengesellschaft Schutzschicht zum schutz eines bauteils gegen korrosion, oxidation und thermische überbeanspruchung sowie verfahren zu ihrer herstellung
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EP2543748A2 (de) 2013-01-09
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WO2010115653A2 (en) 2010-10-14
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CN102482757A (zh) 2012-05-30
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